Removing Outdated Paradigms to Build Sustainable Performance in Manufacturing

Dr A Kenneson-Adams DBA FIoL – Head of Learning, Project7

Introduction

British manufacturing has faced several persistent performance issues over the years, many of which stem from structural, cultural, and systemic challenges. To build a stronger, more inclusive, and diverse manufacturing industry, it’s important to address these old paradigms to embrace greater efficiency, innovation and inclusivity. I will talk about some of these ?challenges, give a few examples, and provide strategies that we have used with our clients to break the trend:

Persistent Performance Issues in British Manufacturing

1. Skills Gap

• Problem: There is still a shortage of workers with advanced technical skills, particularly in areas like automation, digital manufacturing, and robotics. This gap widens as younger generations are less inclined to pursue careers in manufacturing.
• Example: According to Make UK (formerly EEF), up to 81% of manufacturers have struggled to find employees with the right skills for their operations in recent years.

2. Underinvestment in Technology

• Problem: UK manufacturers often lag in adopting cutting-edge technologies like AI, IoT, and Industry 4.0 and 5.0 principles compared to some international competitors, which hinders productivity and competitiveness.
• Example: A 2021 study found that the UK invests less in industrial R&D and automation than manufacturing leaders like Germany and Japan.

3. Lack of Diversity and Inclusion

• Problem: The sector struggles to attract women, ethnic minorities, and other underrepresented groups. This lack of diversity limits creativity and innovation.
• Example: Women represent only 29% of the UK’s manufacturing workforce (2023), and even fewer hold leadership roles.? In fact, in my entire 45-year career, I have only ever worked for 1 female leader and that was in the Royal Air Force.?

4. Fragmented Supply Chains

• Problem: Heavy reliance on global supply chains has exposed vulnerabilities, particularly during crises like Brexit and COVID-19.
• Example: The semiconductor shortage during the pandemic severely disrupted UK automotive and electronics manufacturing.

5. Perception Problem

• Problem: Manufacturing is often perceived as "dirty, dull, and declining," deterring young talent from considering it a viable career path.? In Industry 4.0 this could not be further from the truth.?
• Example: A 2022 study by STEM Learning revealed that many young people in the UK associate manufacturing jobs with low wages and limited career progression.

Strategies to Break the Trend and Build a Stronger, More Inclusive Industry

1. Invest in Skills Development

• Action Plan: Collaborate with schools, colleges, and universities to promote STEM subjects and vocational training.? For example, I partnered with a local Technical Academy to bring industrial learning to the classroom and bring the school to the shop floor to see firsthand what cutting-edge technology looks like.

• Launch apprenticeship programmes with a focus on digital and advanced manufacturing skills.? When we cannot find the right kind of staff for a particular location, ?we work with the business to build their own apprenticeship and leadership training to nurture the right people for the workforce.?
• Provide upskilling opportunities for the current workforce through lifelong learning initiatives, making them available and accessible.?
• Example: Providing simple 30-minute lunch-and-learn sessions to provide upskilling had an immediate impact on maintenance and engineering teams in a paper mill.? Project7 Lean Learning Academy has now trained over 15,000 manufacturing personnel on how to build a culture of Lean manufacturing to build systemic efficiencies.

2. Adopt Advanced Technologies

• Action Plan: Provide financial incentives, like tax breaks or grants, for manufacturers to invest in automation and digital tools. Support small and medium enterprises (SMEs) in implementing Industry 4.0 solutions.? Work with your local manufacturers to build sustainment, they may not be the biggest but may help you avoid the scourge of single sourcing.?
• Example: The UK’s "Made Smarter" initiative helps manufacturers adopt digital technologies to improve productivity and reduce waste.

3. Promote Diversity and Inclusion

• Action Plan: Create targeted campaigns to attract women, ethnic minorities, and neurodiverse individuals to manufacturing roles.? This has been one of the single most valuable strategies I have seen to break paradigms and foster innovation and creativity.? Ensure workplace policies support inclusivity, such as flexible working hours and mentorship programmes.? Inclusivity is not just a hiring policy, but a culture to nurture talent and grow your workforce.
• Example: The Women’s Engineering Society (WES) runs campaigns like "Tomorrow’s Engineers Week" to inspire young girls to pursue careers in manufacturing and engineering.

4. Strengthen Domestic Supply Chains

• Action Plan: Where it is within your span of control encourage reshoring of critical industries and components to reduce reliance on global supply chains. Invest in local suppliers and infrastructure to boost resilience.? The business down the road wants relationships with you on which to build mutual success.?
• Example: Following the COVID-19 pandemic, aerospace manufacturers like Rolls-Royce increased sourcing from UK-based suppliers to mitigate global disruptions.

5. Encourage Exports and Innovation

• Action Plan: Provide export training programmes and guidance to manufacturers on navigating post-Brexit regulations.? Your local chambers of commerce and trade associations have specific experts on staff to help you navigate these hurdles.? Invest in research and development (R&D) to foster innovation and create globally competitive products.
• Example: Jaguar Land Rover (JLR) successfully transitioned to focus on electric vehicles, targeting international markets with cutting-edge designs.? Similar programs exist around the country at local and national government levels which may cost you nothing and provide you with an introduction to foreign markets.

6. Rebrand Manufacturing

• Action Plan: Launch national campaigns to change perceptions, emphasising that manufacturing is high-tech, sustainable, and rewarding.? Change the perspectives and old ways of thinking about manufacturing. Highlight success stories of young professionals and innovators in the field.
• Example: The "Made in Britain" campaign showcases the quality and innovation of British-manufactured products, appealing to both domestic and international audiences.

Why These Changes Matter for the Next Generation

1. Economic Growth: A revitalised manufacturing sector creates high-quality jobs, careers and substantially contributes to your business economic stability.
2. Sustainability: Embracing new IoT and other manufacturing practices can position your business as a leader in environmentally friendly production.
3. Inclusion: A diverse workforce fosters innovation and reflects the values of modern society.
4. Inspiration: By making manufacturing exciting and meaningful, the industry can inspire the next generation to build their careers in this field.

Conclusion

To break the trend of old paradigms that reinforce recurrent issues in British manufacturing, we must commit to change, investing in people and technology to promote inclusivity. As many companies have already seen, embracing a forward-thinking and holistic approach,? in modern manufacturing not only provides an appealing career choice today and for generations to come, but also substantially improves the efficiency, sustainability and profitability of UK manufacturing.?

In my 45 years in industry, I have seen the same recurring issues driven by outdated paradigms stymie business success. However, I have also seen that when individuals step up to make a difference these paradigms can be changed, so I challenge you to be a change agent, to help create the best for your business and for UK manufacturing.?

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